Molded Container with a Structured Varnish Coating

ABSTRACT

An integrally molded container having a structured cured varnish coating that is in direct contact with the surface of the container is provided. The structured cured varnish coating produces one or more visual effects.

FIELD OF THE INVENTION

The present invention relates to an integrally molded container having a structured cured varnish coating that is in direct contact with the surface of the container. The structured cured varnish coating produces one or more visual effects.

BACKGROUND OF THE INVENTION

There are a variety of types of molded articles which are useful in consumer products, both as packaging and as the consumer product itself. Many packages function as both a practical means for transporting/storing the product and as a communication link between the seller and the consumer. Indicia such as labeling, stylized graphics, use of color and contrast, and touch and feel are all signals that can help consumers select the products they desire and forge a strong bond between the consumers and the brands of goods they purchase. When a molded article is the consumer product itself, surface indicia can be a key element of the overall aesthetics of the product.

Special packaging and labels have been created to increase the visual impact on consumers. While some visual effects, such as holographic effects, result in strong visual impact, they are also expensive to produce. Therefore, a need still exists for molded articles that have a strong visual impact at a more economical cost.

SUMMARY OF THE INVENTION

An integrally molded container having a structured cured varnish coating is provided. The structured cured varnish coating produces one or more visual effects. The resulting printed container can give a strong visual impact for both product packaging and as a finished product.

In one embodiment, the container has a fitment for a closure. In another embodiment, the container is a consumer product or package or a component thereof. In a third embodiment, the container includes at least one curved surface and all or a portion of the varnish coating is in direct contact with the curved surface.

In another embodiment, the container includes at least one ruled surface and all or a portion of the varnish coating is in direct contact with the ruled surface. In yet another embodiment, the container includes at least one planar surface and all or a portion of the varnish coating is in direct contact with the planar surface.

In one embodiment, the integrally molded container comprises an article selected from the group consisting of covers, caps, and lids wherein the article has a structured cured varnish coating that is in direct contact with the surface of said article.

In another embodiment, the integrally molded container has a structured cured varnish coating that covers less than 80% of the surface of the container. In an alternative embodiment, the integrally molded container has a structured cured varnish coating that covers more than 80% of the surface of the container. In yet another embodiment, the integrally molded container has the dimensions height (H), width (W) and depth (D) wherein each dimension H, W and D has a length of at least 2 millimeters. In one embodiment, the container comprises one or more thermoplastic polymers.

In another embodiment, an integrally molded container is provided that comprises one or more inks, and a structured cured varnish coating. Furthermore, the varnish coating, inks, or a combination thereof, are in direct contact with the surface of the container. The structured cured varnish coating produces one or more visual effects. In one embodiment, the article is integrally molded. In another embodiment, the article further comprises a hinge or a portion of a hinge. In another embodiment, the article comprises one or more thermoplastic polymers.

In a further embodiment, an impact extruded article having a three dimensional shape is provided comprising a structured cured varnish coating that is in direct contact with the surface of the article. The structured cured varnish coating produces one or more visual effects. In one embodiment, the impact extruded article is a consumer product or package or a component thereof. In another embodiment, the impact extruded article is a container or tube.

In another embodiment, an impact extruded article having a three dimensional shape is provided. It comprises one or more inks, and a structured cured varnish coating. The varnish coating, the inks, or a combination thereof, are in direct contact with the surface of the article. Further, the structured cured varnish coating produces one or more visual effects.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to integrally molded containers having a structured cured varnish coating. The benefits of the invention can be enjoyed in virtually all applications in which molded articles can be used. Molded articles can be used as consumer products, containers, and the like.

As used herein, “cap” means a closure used on container such as a bottle or tube.

As used herein, “closure” means a device used to close or seal a container. Closures can be a cap, cover, lid, plug, film, foil, membrane, etc.

As used herein, “consumable” means a consumer product.

As used herein, “consumer product” means a product intended for use by an individual to clean, maintain and/or improve their body, home, car or personal possessions. Consumer care products include forms such as liquids, gels, suspensions, powders, and the like. Consumer care products may be used in an individual's home or car, or in professional, commercial and/or industrial settings. A representative, non-limiting list of consumer product categories includes antiperspirants, baby care, colognes, commercial products (including wholesale, industrial, and commercial market analogs to consumer-oriented consumer products), cosmetics, deodorants, dish care, feminine protection, hair care, hair color, health care, household cleaners, incontinence care, laundry, oral care, paper products, personal cleansing, disposable absorbent articles, pet health and nutrition, prescription drugs, prestige fragrances, skin care, snacks and beverages, special fabric care, shaving and other hair growth management products, small appliances, devices and batteries. A variety of product forms may fall within each of these product categories. Exemplary product forms and brands are described on The Procter & Gamble Company's website www.pg.com, and the linked sites found thereon. It is to be understood that consumer products that are part of product categories other than those listed above are also contemplated by the present invention, and that alternative product forms and brands other than those disclosed on the above-identified website are also encompassed by the present invention.

As used herein, “container” means an item used to hold or include a product within its volume for storage, dispensing or transportation of that product.

As used herein, “curved surface” means a surface where at least one cross-section of that surface is not a straight line

As used herein, “fiber-formed” means a part produce from a process where a fibrous material, typically containing pulp fibers, is formed to a specific shape in a mold.

As used herein, “forged” means a manufacturing process where metal is shaped by either heating the metal and beating or hammering it into shape or by applying high pressure using a mechanical or hydraulic press.

As used herein, “handle” means a grip attached to an object for using or moving an object. A handle can be integrated directly into an object such as in a detergent bottle, or it can be a separate piece that is fastened to another object.

As used herein, “housing” means an enclosure consisting of 2 or more components that have fastening elements to provide an outer shell that contains functioning components of a device, mechanism, etc.

As used herein, the term “indicia” refers to markings or indications that can be used to convey a message. The message conveyed can be an indication of source, the characteristics of a product in a package, the quantity of a product in a package, the quality of a product in a package, or any other message. Indicia can be a single color such as a light pink to indicate the source of a particular building insulation. Indicia can be a symbol such as a graphic resembling a target used for training archers to indicate a particular retail store. Indicia can be text in any language or combination of languages representative of verbal communication. Indicia can be patterns of colors, lines, or combinations thereof such as that often appearing on Scottish kilts and possibly used to indicate the source of an adhesive tape. Indicia can be illustrations of tangible objects such as an apple indicating the source of a particular brand of computer. Indicia can be artwork depicting tangible objects or imaginary compositions or any kind of marking. A single dot of a single color can be indicia. Indicia can be the type, texture, smell, or sound when rustled of the material used to form a package. Indicia can be a combination of any and all of the indicia described previously.

As used herein, “ink” means a liquid or a paste that carries color carrying components (pigments, dyes, etc.) that is used to color a surface to produce and image, text, or design. Typical inks used in industry are UV (ultra-violet) cured, EB (electron beam) cured, radiation cured, solvent and aqueous. Often inks are in a liquid form and contain at least one pigment or dye. Chemically, many inks are suspensions of organic or inorganic pigments, which are embedded in a polymer resin for stabilization. The carriers of these systems are solvents. Solvents can be water, hydrocarbons or mixtures thereof (e.g. alcohol, esters, acetates, ethers), drying is done thermally or via infrared (IR).

Ink can be placed using any methods known in the art including but not limited to gravure printing, flexographic printing, and offset printing, letter press, lithography, plateless, post press, digital, pad and screen printing. Gravure printing is the direct transfer of liquid ink to substrate from a metal image carrier. The image is lower than the surface of the image carrier base. Flexography printing is the direct transfer of liquid ink to substrate from a photopolymer image carrier. The image is raised above the surface of the image carrier base. Offset printing is the indirect transfer of paste ink to substrate from a rubber ‘blanket’ that is intermediate to substrate and the thin metal image carrier. Examples of plateless printing include electronic printing, ink jet printing, magnetography, ion deposition printing, direct charge deposition printing, and the Mead Cycolor Photocapsule process.

Solvent-based inks can be dried thermally. Once a first ink layer is applied to the film, the solvent contained therein is allowed to or caused to evaporate. Where a printing system such as that described in the aforementioned patent is employed, the solvent preferably is caused to evaporate by means of heat or forced air so as to reduce the amount of time prior to the next ink layers are applied. Once the first ink layer is applied, all subsequent ink layers (if any) are applied in a similar, standard manner.

As used herein, “integrally” means formed from: a single molding operation; and/or using a single piece of material such as a slug, etc; and/or a single shot or co-shot of material.

As used herein, “impact extruded” means a part produced by pushing or drawing a material through a die resulting often in a fixed cross-sectional profile. Starting materials include, but are not limited to, slugs of various metals or thermoplastics in the shape of a disk, cube or other geometry.

As used herein, “molded” means any article produced through a process using a meltable material, commonly thermoplastic polymers, most often starting in the form of small beads or pellets, that are heated until it becomes a molten resin which is then transported, by any of multiple means, into a mold cavity having a particular cavity shape. The plastic is held in the mold cavity, cooled, and then removed as a solidified part having a shape that essentially duplicates the cavity shape of the mold.

As used herein, “non-ruled surface” is defined as a surface meeting the following description: a surface S wherein there is any point on S through which a straight line that lies on S does not exist.

As used herein, “package” means any combination of materials that's function is to hold and protect a product and also serve as a carrier for artwork and visual effects.

As used herein, “planar surface” means a flat two-dimensional surface.

As used herein, the term “primer” refers to a material laid down on a substrate using common printing processes, its main functions being to create (a) adhesion (b) a barrier between the material layer below and a following layer printed thereafter. In this case, promoting “adhesion” means creating a firm connection between the material layer below and a following layer printed thereafter, such that the materials are connected to each other and do not separate under normal usage. Chemically, primers are suspensions of polymer resins in a solvent matrix (mixtures of several hydrocarbons) or suspensions of polymer resins in water. Primers can come as 1-component or 2-component systems, with or without polymerization (thermal drying only). Polymerisation can be triggered chemically (e.g. iso cyanate and urethane), or by radiation (radical or kationic, radiation sources, UV, Electron-beam or other).

As used herein, “radiation curing” refers to exposing a material to ionizing radiation. This polymerizes and/or crosslinks the materials. Useful types of ionizing radiation include UV-light, electron beam (e-beam), X-ray, corona discharge, and the like, with the former being preferred. Regardless of source, the dose of ionizing radiation preferably is sufficiently high to polymerize and crosslink the varnish sufficiently yet not so high so as to degrade the underlying printed markings or the surface of the film

As used herein, “ruled surface” is defined as a surface meeting the following description: a surface S wherein through every point of S there is a straight line that lies on S.

As used herein, “structured cured varnish coating” means a layer of varnish that has been patterned and cured in such a fashion that a nano or micro structure exists on the surface of the layer, wherein the structure forms a visual effect, most commonly produced by light diffraction. The structure exists on the surface of the coating that is opposite the part/varnish interface.

As used herein, “thermoformed” means a part produced from a process where a plastic sheet is heated to a pliable forming temperature, and formed to a specific shape with a mold and/or a plug.

As used herein, “three dimensional shape” means a continuous shape that when measured across the totality of the shape, has non-zero dimension in the x, y, and z directions.

As used herein, the term “varnish” refers to a pigment-free, usually liquid, material that can be cured. Varnishes that are useful in the present invention can be patterned into a diffraction grating and hold that diffraction grating after being cured. The varnish is usually radiation-curable. Preferably, the varnish is UV-curable, meaning it is cured using ultraviolet radiation, or the varnish is EB-cured, meaning it is cured using electron beam radiation. Varnish is transparent, but tints and other coloring agents can be added to the varnish to provide some level of color. In one embodiment, the varnish will be the top layer of any combination of inks+varnish.

As used herein, “visual effect” means a pattern of light that is reflected, diffracted, refracted, or any other optical phenomenon which produces some pattern of light which is visible to the human eye other than typical reflected color. Typical visual effects include holograms, mirror reflectance, color, etc.

As used herein, “welded” means a part formed by joining multiple edges of a single piece of material, or by joining separate pieces of material together by liquefying the places where they are to be bonded allowing the coalesced liquid to solidify resulting such that the bonded area is now a continuous solid. Techniques for welding polymeric parts include energy derived from heat, sonic and frictional sources.

In one embodiment of the present invention, an integrally molded container is provided that comprises a structured cured varnish coating that is in direct contact with the surface of the container. The structured cured varnish coating produces one or more visual effects.

In another embodiment, the integrally molded container has a fitment for a closure. In another embodiment, the container is a consumer product or package or a component thereof.

In one embodiment, the integrally molded container comprises an article selected from the group consisting of covers, caps, and lids wherein the article has a structured cured varnish coating that is in direct contact with the surface of said article.

In another embodiment, the container includes at least one curved surface and all or a portion of said varnish coating is in direct contact with said curved surface. In one embodiment, the container includes at least one ruled surface and all or a portion of the varnish coating is in direct contact with the ruled surface.

In another embodiment, the container includes at least one planar surface and all or a portion of the varnish coating is in direct contact with the planar surface. In one embodiment, the container includes at least one curved surface and all or a portion of the varnish coating is in direct contact with the curved surface.

In another embodiment, the structured cured varnish coating covers less than 80% of the surface of the container. In one embodiment, the container has the dimensions height (H), width (W) and depth (D) wherein each dimension H, W and D has a length of at least 2 millimeters.

In another embodiment of the present invention, an integrally molded container is provided that comprises one or more inks; and a structured cured varnish coating; wherein the varnish coating, the inks, or a combination thereof, are in direct contact with the surface of the container. Further, the structured cured varnish coating produces one or more visual effects. In one embodiment, the container is a consumer product or package or a component thereof.

In another embodiment, the container includes at least one curved surface and all or a portion of the varnish coating is in direct contact with the curved surface. In another embodiment of the present invention, an article is provided that is selected from the group consisting of covers, caps, lids a housing and a handle. The article comprises a structured cured varnish coating that is in direct contact with the surface of the article and the structured cured varnish coating produces one or more visual effect. In one embodiment, the article is integrally molded. In another embodiment, the article further comprises a hinge or a portion of a hinge. In one embodiment, the article selected from the group consisting of covers, caps, lids a housing and a handle comprises one or more thermoplastic polymers

In one embodiment of the present invention, an impact extruded article is provided having a three dimensional shape comprising a structured cured varnish coating that is in direct contact with the surface of the article and the structured cured varnish coating produces one or more visual effects. In another embodiment, the article is a consumer product or package or a component thereof. In one embodiment, the article is a container or tube.

In another embodiment, an impact extruded article is provided having a three dimensional shape comprising one or more inks; and a structured cured varnish coating; wherein the varnish coating, the inks, or a combination thereof, are in direct contact with the surface of the article. The structured cured varnish coating produces one or more visual effects. In another embodiment, the article is a consumer product or package or component thereof. In another embodiment, the article is a container or tube.

In one embodiment, the structured cured varnish coating is formed by the steps of: 1) providing an article or container; 2) applying a layer of radiation-curable varnish to the article 3) impressing a pattern into the varnish, such as by using a structured master film, into the layer of radiation-curable varnish; 4) curing the varnish while the master film is impressed in the varnish layer; 5) removing the master film.

In another embodiment, the structured cured varnish coating is formed by the steps of: 1) providing an article; 2) applying ink, or a combination of ink and a layer of varnish to the article; 3) if ink was applied without varnish, applying a layer of radiation-curable varnish to the article 4) impressing a structured master film into the layer of radiation-curable varnish; 5) curing the varnish while the master film is impressed in the varnish layer; 6) removing the master film.

To improve the adhesion of the ink to the surface of the article or container, the surface of the article or container may be treated or modified before printing. Surface treatments and modifications include: i) mechanical treatments, such as corona treatment, plasma treatment, and flame treatment, and ii) primer treatment. Surface treatments and modifications are known to those of skill in the art.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

What is claimed is:
 1. An integrally molded container comprising a structured cured varnish coating that is in direct contact with the surface of said container, wherein said structured cured varnish coating produces one or more visual effects.
 2. The integrally molded container of claim 1 wherein said container has a fitment for a closure.
 3. The integrally molded container of claim 1 wherein the container is a consumer product or package or a component thereof.
 4. The integrally molded container of claim 1 wherein said container includes at least one curved surface and all or a portion of said varnish coating is in direct contact with said curved surface.
 5. The integrally molded container of claim 1 wherein said container includes at least one ruled surface and all or a portion of said varnish coating is in direct contact with said ruled surface.
 6. The integrally molded container of claim 1 wherein said container includes at least one planar surface and all or a portion of said varnish coating is in direct contact with said planar surface.
 7. The integrally molded container of claim 1 further comprising an article selected from the group consisting of covers, caps, and lids wherein said article comprises a structured cured varnish coating that is in direct contact with the surface of said article.
 8. The integrally molded container of claim 1 wherein the structured cured varnish coating covers less than 80% of the surface of the container.
 9. The integrally molded container of claim 1 wherein said container has the dimensions height (H), width (W) and depth (D) wherein each dimension H, W and D has a length of at least 2 millimeters.
 10. The integrally molded container of claim 1 wherein said container comprises one or more thermoplastic polymers.
 11. An integrally molded container comprising: a. one or more inks; and b. a structured cured varnish coating; wherein said varnish coating, said inks, or a combination thereof, are in direct contact with the surface of said container, and further, wherein said structured cured varnish coating produces one or more visual effects.
 12. The integrally molded container of claim 11 wherein the container is a consumer product or package or a component thereof.
 13. The integrally molded container of claim 11 wherein said container includes at least one curved surface and all or a portion of said varnish coating is in direct contact with said curved surface.
 14. An article selected from the group consisting of covers, caps, lids, housings and handles wherein the article comprises a structured cured varnish coating that is in direct contact with the surface of said article, wherein said structured cured varnish coating produces one or more visual effect.
 15. The article of claim 14 wherein said article is integrally molded.
 16. The article of claim 14 further comprising a hinge or a portion of a hinge.
 17. The article of claim 14 wherein said article comprises one or more thermoplastic polymers.
 18. An impact extruded article having a three dimensional shape comprising a structured cured varnish coating that is in direct contact with the surface of said article, wherein said structured cured varnish coating produces one or more visual effects.
 19. The impact extruded article of claim 18 wherein the article is a consumer product or package or a component thereof.
 20. The impact extruded article of claim 18 wherein the article is a container or tube.
 21. A impact extruded article having a three dimensional shape comprising: a. one or more inks; and b. a structured cured varnish coating; wherein said varnish coating, said inks, or a combination thereof, are in direct contact with the surface of said article, and further, wherein said structured cured varnish coating produces one or more visual effects.
 22. The impact extruded article of claim 21 wherein the article is a consumer product or package or component thereof.
 23. The impact extruded article of claim 21 wherein the article is a container or tube. 